US9019061B2 - Magnetic device formed with U-shaped core pieces and power converter employing the same - Google Patents
Magnetic device formed with U-shaped core pieces and power converter employing the same Download PDFInfo
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- US9019061B2 US9019061B2 US12/751,650 US75165010A US9019061B2 US 9019061 B2 US9019061 B2 US 9019061B2 US 75165010 A US75165010 A US 75165010A US 9019061 B2 US9019061 B2 US 9019061B2
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F30/00—Fixed transformers not covered by group H01F19/00
- H01F30/06—Fixed transformers not covered by group H01F19/00 characterised by the structure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F37/00—Fixed inductances not covered by group H01F17/00
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M1/00—Details of apparatus for conversion
- H02M1/42—Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
- H02M1/4208—Arrangements for improving power factor of AC input
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F38/00—Adaptations of transformers or inductances for specific applications or functions
- H01F38/02—Adaptations of transformers or inductances for specific applications or functions for non-linear operation
- H01F38/023—Adaptations of transformers or inductances for specific applications or functions for non-linear operation of inductances
- H01F2038/026—Adaptations of transformers or inductances for specific applications or functions for non-linear operation of inductances non-linear inductive arrangements for converters, e.g. with additional windings
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
- H01F27/263—Fastening parts of the core together
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
- H01F3/12—Magnetic shunt paths
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
- H01F3/14—Constrictions; Gaps, e.g. air-gaps
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- H02M2003/1586—
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M3/00—Conversion of dc power input into dc power output
- H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
- H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
- H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
- H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
- H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
- H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
- H02M3/158—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
- H02M3/1582—Buck-boost converters
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M3/00—Conversion of dc power input into dc power output
- H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
- H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
- H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
- H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
- H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
- H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
- H02M3/158—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
- H02M3/1584—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load with a plurality of power processing stages connected in parallel
- H02M3/1586—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load with a plurality of power processing stages connected in parallel switched with a phase shift, i.e. interleaved
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B70/00—Technologies for an efficient end-user side electric power management and consumption
- Y02B70/10—Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes
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- Y02B70/126—
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
Definitions
- the present invention is directed, in general, to power electronics and, more specifically, to a magnetic device employable in a power converter.
- a switched-mode power converter (also referred to as a “power converter” or “regulator”) is a power supply or power processing circuit that converts an input voltage waveform into a specified output voltage waveform.
- DC-DC power converters convert a direct current (“dc”) input voltage into a dc output voltage.
- Controllers associated with the power converters manage an operation thereof by controlling the conduction periods of power switches employed therein.
- the controllers are coupled between an input and output of the power converter in a feedback loop configuration (also referred to as a “control loop” or “closed control loop”).
- power converters To produce a dc output voltage, power converters employ magnetic devices such as inductors and transformers.
- a high-frequency alternating current (“ac”) voltage is applied to a winding of the magnetic device that is typically converted to another voltage level by an inductive action of the magnetic device.
- the converted voltage level is rectified by a diode or an active semiconductor device to produce the dc output voltage.
- magnetic devices are often formed with windings wound in a single layer to reduce the proximity effect produced by high-frequency currents flowing in a proximate winding turn.
- the proximity effect causes high-frequency currents to flow predominantly in only a portion of a conductive winding, thereby increasing the effective resistance of the winding.
- Magnetic devices are conventionally constructed with rectilinear core pieces such as “E” and “I” core pieces employed to form a high-frequency transformer or inductor. From practical manufacturing considerations, such designs require that a single-layer winding be formed on the vertical walls of the “E” portion of the magnetic core. Designs with such winding structures do not utilize the horizontal walls of the “E” or the “I” core pieces of the magnetic core, and accordingly introduce a high level of power losses.
- the magnetic device includes a rectilinear core piece formed of a magnetic material, and first and second U-shaped core pieces positioned on the rectilinear core piece.
- the magnetic device also includes first and second conductive windings formed about the first and second U-shaped core pieces, respectively.
- FIG. 1 illustrates a block diagram of an embodiment of a power converter constructed according to the principles of the present invention
- FIGS. 2 to 4 illustrate schematic diagrams of exemplary power trains employable in a power converter constructed according to the principles of the present invention.
- FIGS. 5 to 9 illustrate diagrams of embodiments of magnetic devices constructed according to the principles of the present invention.
- the present invention will be described with respect to exemplary embodiments in a specific context, namely, a magnetic device including a U-shaped core piece, and a method of forming the same.
- the magnetic device including a U-shaped core piece provides improved power conversion efficiency by accommodating a larger physical space for turns of a single-layer winding of a conductive material formed thereabout. While the principles of the present invention will be described in the environment of a magnetic device for a power converter, any application that may benefit from a magnetic device such as a power amplifier or a motor controller is well within the broad scope of the present invention.
- FIG. 1 illustrated is a block diagram of an embodiment of a power converter including a magnetic device constructed according to the principles of the present invention.
- the power converter is coupled to a source of electrical power such as an ac mains represented by the ac power source providing an input voltage V in .
- the power converter includes a power train 105 that is controlled by a controller 110 .
- the controller 110 generally measures an operating characteristic of the power converter such as an output voltage V c and controls a duty cycle D of one or more power switches therein in response to the measured operating characteristic to regulate the characteristic.
- the power converter may form a section of a power supply and provide power to another subsystem thereof, such as an isolating dc-dc power converter coupled to an output thereof that provides a regulated voltage to a load.
- the power train 105 may employ a boost topology as described herein.
- the power train 105 of the power converter includes a plurality of power switches coupled to a magnetic device to provide the power conversion function.
- FIG. 2 illustrated is a schematic diagram of an exemplary power train (including a boost topology) 201 employable in a power converter constructed according to the principles of the present invention.
- the power train 201 of the power converter receives an input voltage V in (e.g., an unregulated ac input voltage) from a source of electrical power such as ac mains at an input thereof and provides a regulated output voltage V C at output terminals 205 , 206 of the power converter.
- V in e.g., an unregulated ac input voltage
- V C output voltage
- the output voltage V C is generally higher than the input voltage V in such that a switching operation thereof can regulate the output voltage V C .
- a main power switch S 1 (e.g., an N-channel metal-oxide semiconductor (“NMOS”) active switch or switch) is enabled to conduct by a gate drive signal GD for a primary interval and couples the input voltage V in through a rectifier bridge 203 to a boost inductor L boost .
- NMOS metal-oxide semiconductor
- a main power switch S 1 is enabled to conduct by a gate drive signal GD for a primary interval and couples the input voltage V in through a rectifier bridge 203 to a boost inductor L boost .
- NMOS metal-oxide semiconductor
- the duty cycle for the power train 201 depends in steady state on the ratio of the input and output voltages V in , V c , respectively, according to the equation:
- auxiliary power switch e.g., the diode D 1
- the auxiliary power switch D 1 may include a second active power switch that is controlled to conduct by a complementary gate drive signal.
- the auxiliary power switch D 1 provides a path to maintain the continuity of the input current i in flowing through the boost inductor L boost .
- the input current i in flowing through the boost inductor L boost decreases, and may become zero and remain zero for a period of time resulting in a “discontinuous conduction mode” of operation.
- the input current i in flowing through the boost inductor L boost flows through the diode D 1 (i.e., the auxiliary power switch) into an output filter capacitor C.
- the duty cycle of the main power switch S 1 (and the complementary duty cycle of the auxiliary power switch D 1 ) may be adjusted to maintain a regulation of the output voltage V C of the power converter.
- conduction periods for the main and auxiliary power switches S 1 , D 1 may be separated by a small time interval by the use of “snubber” circuit elements (not shown) or by control circuit timing to avoid cross conduction current therebetween, and beneficially to reduce the switching losses associated with the power converter.
- the boost inductor L boost is preferably formed with a single-layer winding as described previously hereinabove to reduce power loss associated with the proximity effect.
- the power train 300 includes a first boost regulator subcircuit including a first boost inductor L boost1 , a first diode D 1 , and a first power switch S 1 that receives a first drive signal GD S1 .
- the power train 300 includes a second boost regulator subcircuit including a second boost inductor L boost2 , a second diode D 2 , and a second power switch S 2 that receives a second drive signal GD S2 .
- the first and second boost regulator subcircuits are generally controlled to operate roughly 180 degrees out of phase with respect to each other.
- Out-of-phase operation of the boost regulator subcircuits provides an interleaving effect that doubles the ripple frequency and reduces the ripple magnitude for the current drawn from a rectifier bridge 303 and hence an ac input current i in .
- a similar effect is achieved for the current supplied to the output filter capacitor C.
- the reduction of switching ripple magnitude in the input current i in helps reduce filtering requirements for an input filter (not shown) to reduce undesirable high-frequency components that may be conducted back to a source of electrical power such as an ac mains.
- Substantial benefits accrue from the interleaving effects between the two boost regulator subcircuits.
- the first and second boost inductors L boost1 , L boost2 are formed with single-layer windings in a magnetic structure. Remaining circuit elements in FIG. 3 and in following FIGUREs that are similar to those in FIG. 2 and will not be described again in the interest of brevity.
- FIG. 4 illustrated is a schematic diagram of an exemplary power train employable in a power converter constructed according to the principles of the present invention. More specifically, the power train employs a boost topology with two interleaved boost regulator subcircuits and a boost inductor L boost formed by a magnetic device.
- the magnetic device includes a common conductive winding or winding N C (coupled between terminals 1 and 2 of the magnetic device), a first conductive winding or winding N S1 (coupled between terminals 2 and 3 ), and a second conductive winding or winding N S2 (coupled between terminals 2 and 4 ).
- the first and second windings N S1 , N S2 are electrically and magnetically coupled to the common winding N C .
- the first and second windings N S1 , N S2 have equal numbers of turns and will hereinafter be represented with a reference symbol N S . Dots are illustrated in FIG. 4 adjacent to the windings to indicate the sense of each winding (i.e., the winding direction and the sense of the magnetically induced voltage therein).
- the interleaved boost regulator subcircuits are controlled by a control circuit or controller (not shown) to provide an input current with high-power factor.
- One boost regulator subcircuit includes a first diode D 1 and a first power switch S 1 , and a portion of the magnetic device that includes the common winding N c and the first winding N S1 .
- the other boost regulator subcircuit includes a second diode D 2 and a second power switch S 2 , and a portion of the magnetic device that includes the common winding N c and the second winding N S2 .
- the output currents i 1 , i 2 from the boost regulator subcircuits of the power train are interleaved and flow through the first and second diodes D 1 , D 2 , respectively, into an output filter capacitor C.
- the input currents to the boost regulator subcircuits are interleaved and form the input current i in , through the common winding N c .
- the first and second power switches S 1 , S 2 are controlled by first and second control signals GD S , GD S2 , respectively, to provide duty-cycle control for each of the two interleaved boost regulator subcircuits.
- the first and second control signals GD S1 , GD S2 may be controlled 180 degrees out of phase with respect to each other, and provide a common duty cycle D for each boost regulator subcircuit.
- a load, represented by current source 408 is coupled to output terminals 405 , 406 of the power converter and draws an output current i o .
- a common winding N C with selected turns has been described herein as being formed around a center leg of a magnetic core of the magnetic device.
- the common winding N C with selected turns may be formed around a common leg of a magnetic core that is not geometrically a center leg.
- the terms “center” and “common” as illustrated and used herein with reference to a leg of a magnetic core have a similar meaning, and include a leg of a magnetic core that may not be geometrically located as a center leg.
- the magnetic device is a boost inductor L boost with rectilinear construction and with single-layer windings.
- the magnetic device includes the common winding N c wound around a common leg 505 of the magnetic core, which may be a center leg of the magnetic core, and be electrically and magnetically coupled to first and second windings N S1 , N S2 , each formed in a single layer, and each wound around separate legs (e.g., first and second outer legs 510 , 515 , respectively) of the magnetic core.
- a common flux ⁇ c flows through the common leg 505 of the magnetic core.
- First and second fluxes ⁇ 1 , ⁇ 2 flow through the first and second outer legs 510 , 515 , respectively, of the magnetic core.
- the first and second windings N S1 , N S2 are each conventionally formed as a single layer on the vertical walls of the “E” portion of the magnetic core, which limits the electrical conductivity of these windings.
- Terminals 1 , 2 , 3 , and 4 of the magnetic device illustrated in FIG. 5 correspond to terminals similarly numbered and described with reference to FIG. 4 .
- a gap 520 e.g., an air gap or a gap of other substantially nonmagnetic material
- gaps can be formed between the upper surfaces of the first and second outer legs 510 , 515 and/or the lower surface of the upper cross-member 525 .
- gaps can be formed between upper surfaces of all the legs 505 , 510 , 515 and the lower surface of the upper cross-member 525 .
- the sense of the winding directions is illustrated by the drawings of the windings N C , N S1 , N S2 in FIG. 5 .
- the sense of all the windings N C , N S1 , N S2 can be reversed to produce the same result, but with magnetic fluxes flowing in opposite directions.
- the first and second windings N S1 , N S2 can be electrically coupled together external to the magnetic device.
- the common winding N C can be separated into two winding parts that can be electrically coupled together external to the magnetic device.
- the magnetic device includes first and second U-shaped core pieces 602 , 603 , separated by a rectilinear core piece or central rectilinear core piece 601 (formed of a magnetic material).
- the first and second U-shaped core pieces 602 , 603 form a portion of a toroidal core and are preferably formed of high permeability magnetic material, such as a soft ferrite.
- the conductive windings such as first and second conductive windings or windings N s1 , N s2 , are each formed about, along substantially the full span or substantially an entire curved length of the first and second U-shaped core pieces 602 , 603 , respectively.
- a third conductive winding or winding (e.g., a common or center conductive winding) N c is formed about the rectilinear core piece 601 , and is electrically coupled to said first and second conductive windings N s1 , N s2 .
- the magnetic device illustrated herein integrates and couples three inductors into one magnetic device.
- FIG. 7 illustrated is a diagram of an embodiment of a magnetic device constructed according to the principles of the present invention.
- the magnetic device includes first and second U-shaped core pieces 702 , 703 .
- the first and second U-shaped core pieces 702 , 703 are now positioned on a common surface of a rectilinear core piece or central rectilinear core piece 701 .
- the first and second U-shaped core pieces 702 , 703 are again preferably formed of high permeability magnetic material, such as a magnetic material with a relative permeability greater than 50.
- the first and second U-shaped core pieces 702 , 703 may be formed of a soft ferrite.
- the first and second conductive windings or windings N s1 , N s2 may each be formed about or along substantially the full span of the first and second U-shaped core pieces 702 , 703 , respectively.
- the first and second conductive windings N s1 , N s2 are illustrated spanning only a portion of the first and second U-shaped core pieces 702 , 703 , respectively.
- a third conductive winding or winding (e.g., a common or center conductive winding) N c which may be formed as a staple, is again formed about the rectilinear core piece 701 .
- the center leg 505 of the magnetic device includes a gap or low-permeability “spacer” 520 in which a substantial portion of the magnetic energy of the magnetic device is stored.
- gaps may be included in the flux paths of the outer legs formed by the first and second U-shaped core pieces.
- a gap can be formed, without limitation, of a nonmagnetic material or a magnetic material of low permeability such as air, a plastic material, or a powdered soft ferrite distributed in a nonmagnetic matrix such as a resin or an epoxy.
- FIG. 8 illustrated is a diagram of an embodiment of a magnetic device constructed according to the principles of the present invention.
- the magnetic device includes first and second U-shaped core pieces 802 , 803 positioned on a common surface of the rectilinear core piece or central rectilinear core piece 801 .
- First and second gaps 804 , 805 which may be formed of nonmagnetic spacers, are positioned between the first and second U-shaped core pieces 802 , 803 , respectively, and the rectilinear core piece 801 to reduce mismatch of magnetic flux in the first and second U-shaped core pieces 802 , 803 due to currents flowing in first and second conductive windings N s1 , N s2 .
- a third conductive winding or winding (e.g., a common or center conductive winding) N c is formed about the rectilinear core piece 801 .
- the magnetic device includes first and second U-shaped core pieces 902 , 903 positioned on a common surface of a rectilinear core piece or central rectilinear core piece 901 .
- the rectilinear core piece 901 is constructed of magnetic material with a distributed gap. In other words, it is constructed of a magnetic material with a lower relative permeability than the relative permeability of the first and second U-shaped core pieces 902 , 903 , such as a powdered soft ferrite distributed in a nonmagnetic matrix such as a resin or an epoxy.
- a gap is formed in series with flux flowing in a common or center leg (e.g., the rectilinear core piece 901 ) of the magnetic structure, as well as gaps formed in series with flux flowing in the outer legs (e.g., the first and second U-shaped core pieces 902 , 903 ).
- Such use of disparate magnetic materials, such as a higher relative magnetic permeability of the first and second U-shaped core pieces 902 , 903 compared to the relative magnetic permeability of the rectilinear core piece 901 enables construction of a magnetic structure without the need to insert physical spacers to produce series low-permeability gaps, and without the need to accurately shorten the center or common leg of an “E” core piece to produce a series air gap for a flux flowing therein, thereby reducing a manufacturing cost.
- the magnetic device includes a rectilinear core piece formed of a magnetic material.
- the rectilinear core piece may be formed with a distributed air gap.
- the magnetic device also includes first and second U-shaped core pieces formed of a high relative permeability magnetic material and positioned on the rectilinear core piece.
- the first and second U-shaped core pieces may be positioned on a common surface of the rectilinear core piece, and may form a portion of a toroidal core.
- a nonmagnetic spacer may be positioned between one of the first and second U-shaped core pieces and a surface of the rectilinear core piece.
- a relative permeability of the rectilinear core piece is substantially lower than the relative permeability of the first and second U-shaped core pieces.
- the magnetic device also includes first and second conductive windings formed about the first and second U-shaped core pieces, respectively.
- the first and second conductive windings may be formed over substantially an entire curved length of the first and second U-shaped core pieces, respectively.
- the magnetic device may also include a third conductive winding (e.g., a common or center conductive winding, or as a staple) formed about the rectilinear core piece, and electrically coupled to the first and second conductive windings.
- a power converter including a magnetic device including U-shaped core pieces positioned on a rectilinear core piece and related methods of forming the same are submitted for illustrative purposes only. While a magnetic structure has been described in the environment of a power converter, the magnetic structure may also be applied to other systems such as, without limitation, a power amplifier and a motor controller.
Abstract
Description
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Priority Applications (1)
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US12/751,650 US9019061B2 (en) | 2009-03-31 | 2010-03-31 | Magnetic device formed with U-shaped core pieces and power converter employing the same |
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US16518409P | 2009-03-31 | 2009-03-31 | |
US12/751,650 US9019061B2 (en) | 2009-03-31 | 2010-03-31 | Magnetic device formed with U-shaped core pieces and power converter employing the same |
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US20100254168A1 US20100254168A1 (en) | 2010-10-07 |
US9019061B2 true US9019061B2 (en) | 2015-04-28 |
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CN (1) | CN102356438B (en) |
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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US20150084422A1 (en) * | 2012-03-19 | 2015-03-26 | Kabushiki Kaisha Toyota Chuo Kenkyusho | Magnetic component, power converter and power supply system |
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